Composite Film for Cable Wrapping Layer
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Solution Overview
Problem
The existing materials used for wrapping layers in cables are prone to loose wrapping, leading to misalignment and poor wrapping effects due to high requirements for wrapping technique, such as wrapping pitch and tension, necessitating a material with improved bonding and mechanical properties.
Innovation Solution
A composite film for cable wrapping layers comprising a polyethylene (PE) film layer, a polyethylene terephthalate (PET) film layer, an aluminum foil layer, and a bonding layer, with specific raw material compositions and processing methods to enhance bonding strength, tensile strength, and electromagnetic shielding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional wrapping materials (glass tape, PVC tape, non-woven tape, mica tape) are used to surround and fasten conductors, then the wrapping process can be completed, but the wrapping layer becomes loose and conductors become misaligned due to high requirements for wrapping technique
Solution Approach 1:
The patent uses a composite film structure consisting of multiple layers: a PE film layer for self-bonding to the insulation layer, a PET film layer for structural support, an aluminum foil layer for electromagnetic shielding, and a bonding layer to integrate all components. This composite structure provides both automatic bonding capability and mechanical strength, eliminating the need for precise wrapping technique while ensuring wrapping stability.
Solution Approach 2:
The PE film layer is designed to automatically bond to the insulation layer through self-adhesion properties, eliminating the need for additional bonding operations or precise manual adjustment during wrapping. The material performs the bonding function automatically, reducing operational complexity while maintaining reliability.
2Manufacturing precision
If wrapping pitch, wrapping angle, and wrapping tension are strictly controlled to achieve tight wrapping, then the wrapping effect is improved, but the process complexity and time consumption increase
Solution Approach 1:
The composite film's self-bonding PE layer automatically adheres to the insulation layer upon contact, eliminating the need for precise control of wrapping pitch, angle, and tension. The material itself ensures tight wrapping through its adhesive properties, significantly simplifying the wrapping process control while maintaining high manufacturing precision.
Solution Approach 2:
The patent changes the fundamental parameter of wrapping from mechanical constraint (tight twisting) to chemical/adhesive bonding (self-adhesion of PE layer). This parameter change allows the wrapping to maintain tightness without requiring precise control of wrapping parameters, reducing process complexity.
3Strength
If conventional wrapping materials are used, then the basic wrapping function is achieved, but the bonding force to insulation layer, tensile strength, and tear resistance are insufficient
Solution Approach 1:
The patent employs a multi-layer composite film where each layer contributes specific properties: PE layer for bonding, PET layer for tensile strength, aluminum foil for shielding, and bonding layer for integration. This composite approach achieves superior bonding force and mechanical strength while keeping the manufacturing process simple through lamination technology.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The composite film provides improved bonding force, tensile strength, tear resistance, and electromagnetic shielding, preventing conductor misalignment and reducing defective cables, thus enhancing wrapping efficiency and stability.
Implementation Method 1
the bonding force of the composite film with a self-bonding effect to the insulation layer is improved by means of the residual temperature of a surface of the processed insulation layer
Implementation Method 2
aluminum foil, as a conductive material, has an excellent electromagnetic shielding effect
Implementation Method 3
a polyethylene terephthalate (PET) film layer laminated at the PE film layer
Data Source
AI summary
This application provides a composite film for a cable wrapping layer and a preparation method for the same. The composite film for the cable wrapping layer includes a PE film layer, a PET film layer laminated at the PE film layer, an aluminum foil layer laminated at the PET film layer, and a bonding layer arranged between the PET film layer and the aluminum foil layer. The PE film layer is made of raw materials having the following parts by weight: 40-45 parts of LLDPE with a melt index of 0.9-1.1 g/10 min and a density of 0.920-0.922 g/cm3, 35-40 parts of m-LLDPE with a melt index of 1.9-2.1 g/10 min and a density of 0.917-0.920 g/cm3 and 15-25 parts of ethylene-vinyl acetate copolymer.